EP0563148A1 - Procedes de couchage. - Google Patents

Procedes de couchage.

Info

Publication number
EP0563148A1
EP0563148A1 EP92901417A EP92901417A EP0563148A1 EP 0563148 A1 EP0563148 A1 EP 0563148A1 EP 92901417 A EP92901417 A EP 92901417A EP 92901417 A EP92901417 A EP 92901417A EP 0563148 A1 EP0563148 A1 EP 0563148A1
Authority
EP
European Patent Office
Prior art keywords
coating
layer
liquid material
curtain
low viscosity
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP92901417A
Other languages
German (de)
English (en)
Other versions
EP0563148B1 (fr
Inventor
Terence Desmond Blake
Rosemary Barnes
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kodak Ltd
Eastman Kodak Co
Original Assignee
Kodak Ltd
Eastman Kodak Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Kodak Ltd, Eastman Kodak Co filed Critical Kodak Ltd
Publication of EP0563148A1 publication Critical patent/EP0563148A1/fr
Application granted granted Critical
Publication of EP0563148B1 publication Critical patent/EP0563148B1/fr
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Classifications

    • G—PHYSICS
    • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03C—PHOTOSENSITIVE MATERIALS FOR PHOTOGRAPHIC PURPOSES; PHOTOGRAPHIC PROCESSES, e.g. CINE, X-RAY, COLOUR, STEREO-PHOTOGRAPHIC PROCESSES; AUXILIARY PROCESSES IN PHOTOGRAPHY
    • G03C1/00—Photosensitive materials
    • G03C1/74—Applying photosensitive compositions to the base; Drying processes therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C5/00—Apparatus in which liquid or other fluent material is projected, poured or allowed to flow on to the surface of the work
    • B05C5/007—Slide-hopper coaters, i.e. apparatus in which the liquid or other fluent material flows freely on an inclined surface before contacting the work
    • B05C5/008—Slide-hopper curtain coaters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/30—Processes for applying liquids or other fluent materials performed by gravity only, i.e. flow coating
    • B05D1/305—Curtain coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C9/00—Apparatus or plant for applying liquid or other fluent material to surfaces by means not covered by any preceding group, or in which the means of applying the liquid or other fluent material is not important
    • B05C9/06—Apparatus or plant for applying liquid or other fluent material to surfaces by means not covered by any preceding group, or in which the means of applying the liquid or other fluent material is not important for applying two different liquids or other fluent materials, or the same liquid or other fluent material twice, to the same side of the work
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2451/00—Type of carrier, type of coating (Multilayers)
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/50—Multilayers
    • B05D7/52—Two layers
    • B05D7/54—No clear coat specified
    • B05D7/548—No curing step for the last layer
    • B05D7/5483—No curing step for any layer
    • B05D7/5485—No curing step for any layer the two layers being applied simultaneously
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/50—Multilayers
    • B05D7/56—Three layers or more
    • B05D7/58—No clear coat specified
    • B05D7/588—No curing step for the last layer
    • B05D7/5883—No curing step for any layer
    • B05D7/5885—No curing step for any layer all layers being applied simultaneously
    • G—PHYSICS
    • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03C—PHOTOSENSITIVE MATERIALS FOR PHOTOGRAPHIC PURPOSES; PHOTOGRAPHIC PROCESSES, e.g. CINE, X-RAY, COLOUR, STEREO-PHOTOGRAPHIC PROCESSES; AUXILIARY PROCESSES IN PHOTOGRAPHY
    • G03C1/00—Photosensitive materials
    • G03C1/74—Applying photosensitive compositions to the base; Drying processes therefor
    • G03C2001/7433—Curtain coating
    • G—PHYSICS
    • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03C—PHOTOSENSITIVE MATERIALS FOR PHOTOGRAPHIC PURPOSES; PHOTOGRAPHIC PROCESSES, e.g. CINE, X-RAY, COLOUR, STEREO-PHOTOGRAPHIC PROCESSES; AUXILIARY PROCESSES IN PHOTOGRAPHY
    • G03C1/00—Photosensitive materials
    • G03C1/74—Applying photosensitive compositions to the base; Drying processes therefor
    • G03C2001/7462—Flowing conditions in slots prior to coating
    • G—PHYSICS
    • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03C—PHOTOSENSITIVE MATERIALS FOR PHOTOGRAPHIC PURPOSES; PHOTOGRAPHIC PROCESSES, e.g. CINE, X-RAY, COLOUR, STEREO-PHOTOGRAPHIC PROCESSES; AUXILIARY PROCESSES IN PHOTOGRAPHY
    • G03C1/00—Photosensitive materials
    • G03C1/74—Applying photosensitive compositions to the base; Drying processes therefor
    • G03C2001/7481—Coating simultaneously multiple layers

Definitions

  • This invention relates to coating processes and is more particularly concerned with curtain coating processes.
  • curtain coating as described in
  • one or more liquid layers are applied to a moving support as a freely- falling curtain. Under properly controlled conditions, uniform coatings are achieved in which each layer retains its separate identity.
  • the curtain can be formed using a conventional multilayer slide hopper fitted with a suitable lip. Edging rods may be used to maintain the width of the curtain, and surface active agents are frequently added to the outer layers to improve curtain stability and promote uniform deposition.
  • coating speed One important variable which affects the "coating window” is coating speed. For economic reasons, high coating speeds are desirable provided they can be achieved with low waste and without loss of product quality. However, a major problem with high speed coating is that if the speed is too high, the liquid fails to wet the support in a complete and steady manner. When this occurs, air is entrained at the wetting line and causes patchy or uneven deposition of the coating.
  • Air-entrainment is believed to occur whenever the dynamic contact angle formed between the liquid and the support at the wetting line approaches its limiting value of 180°.
  • the coating speed at which this happens depends on many factors such as the method of coating and the physical properties of the liquid.
  • the viscosity of the liquid being brought into contact with the support at the wetting line is of particular importance.
  • the occurrence of air-entrainment can be postponed to higher speeds by reducing the viscosity of the liquid.
  • the ability to coat at high viscosities has several advantages such as reduced drying load and improved uniformity.
  • a liquid having a relatively low viscosity typically 3 to 5mPas
  • the bottom layer is added to the higher viscosity liquids out of the bottom slot of the hopper (that is, the slot nearest the bead) .
  • US-A-4569863 discloses a curtain coating process for applying a multiple coating on to a moving support.
  • the process enables a plurality of comparatively high viscosity layers (having viscosities greater than 50mPas) to be applied to the support at coating speeds of 400mmin ⁇ or more.
  • This is achieved by the use of a thin bottom layer (otherwise called an accelerating layer) of lower viscosity.
  • the thickness of this layer is between 2 and 30mm, and its viscosity between 1 and 20mPas.
  • the thickness is between 2.5 and 5mm, and the viscosity between 2 and 3mPas.
  • the use of an upper spreading layer is also disclosed.
  • the bottom or accelerating layer is applied directly to the back of the curtain either by discharging the layer from the bottom slot of a conventional slide hopper, or from a slot which flows on to a separate slide which joins at the hopper lip the main hopper slide on which are flowing the other layer compositions. Hoppers designed for this purpose are sometimes known as V-hoppers.
  • the freely-falling curtain impinges on to the moving support at an application angle of 0°.
  • the application angle may be defined as the slope angle of the support at the point of impingement of the freely- falling and substantially vertical curtain measured as a declination from the horizontal in the direction of coating.
  • the height of the curtain is restricted within the range of 10 to 100mm, preferably 15 to 50mm.
  • US-A-4569863 may also increase the undesirable tendency of the plane of the curtain to deviate from the vertical, and bend backwards towards the hopper.
  • the low viscosity layer which wets the support is delivered using a V-hopper, it faces in a downward direction.
  • the establishment of flow on such a slide can be difficult in practice, and dripping of composition off the slide surface may occur.
  • there is a component of gravity normal to the slide surface which is de-stabilizing and promotes the growth of waves on the layer as it travels down the slide.
  • a low viscosity bottom layer also promotes "puddling" at the point where the freely-falling liquid curtain impinges on the moving support.
  • a "heel” appears at the foot of the curtain. If the heel is sufficiently large, it may contain an eddy in which air bubbles and debris may become trapped, thereby generating a line or streak in the coating. A large heel can also oscillate, producing non-uniformities in the coating along and across the direction of web motion.
  • the low viscosity bottom layer may have to be kept thin, even though a functional bottom layer may not be thin, and the curtain height low, though this adversely affects curtain stability and restricts the room beneath the hopper for other equipment, such as a start pan.
  • a curtain coating process in which liquid material comprising two or more layers is coated on to a moving support, and the layer of liquid material adjacent the support has a viscosity which is less than ImPas.
  • the bottom layer of low viscosity liquid readily wets the support at high coating speeds and is applied with the curtain as the bottom layer of the liquid material being coated.
  • the liquid material to comprise one or more layers of much higher viscosity, which, in the absence of the bottom layer, would not wet the support so readily and which would, therefore, be more difficult to coat without air-entrainment except at much lower speeds.
  • the bottom layer may be any low viscosity liquid or solution compatible with the remainder of the liquid material. If the latter comprises aqueous coating compositions, as in the manufacture of photographic products, then the preferred liquid for the bottom layer is water to which small amounts of othe .substances, such as surfactants, hardeners, dyes etc., may be added as necessary.
  • the advantages of high viscosity coating are combined with low viscosity wetting.
  • High coating speeds are possible, and the coating speed at which air-entrainment occurs is less seriously affected by the total flow rate.
  • the viscosities of the layers comprising the main bulk of the curtain may be chosen to suit factors other than wetting such as uniformity, product specification and the drying capacity of the coating track.
  • the low viscosity bottom layer may also be very thin (between 0.5 and 10mm). This minimizes the tendency towards puddling and lessens the necessity for the incorporation of non-functional materials.
  • a further advantage of using a thin bottom layer is that diffusion into other layers occurs very rapidly, hence flow after coating is minimized.
  • Figure 1 is a schematic cross-section of a curtain coating hopper used in accordance with the present invention
  • Figure 2 is schematic partial cross-section of a hopper illustrating an exit slot for a low viscosity bottom layer
  • Figure 3 is similar to Figure 2, but illustrates an alternative exit slot arrangement for a low viscosity bottom layer
  • FIG 4 is a schematic cross-section of a curtain coating hopper, but illustrating the use of exit slots as shown in Figures 2 or 3.
  • a conventional multilayer curtain-coating slide hopper 10 is shown in Figure 1.
  • One method of applying a freely-falling curtain 12 to a moving support 14 is shown, although the support is preferably backed by a precision roller (not shown) .
  • the hopper 10 is oriented relative to the moving support 14 so that the liquid layers flow down the slide surface 28 in a direction opposite to the coating direction.
  • Layer 16 (which wets the support 14), although uppermost on the slide surface 28, becomes the bottom layer of the coating as the curtain 12 impinges on the support 14.
  • the other layers are discharged from respective slots 20, 22, 24 and 26, and are inverted in sequence from that of conventional curtain- or bead- coating.
  • the support 14 is inclined to the horizontal so that the angle of application of the curtain to the support, a, is not 0°, that is, the curtain 12 is applied at a forward application angle.
  • an exit slot arrangement is shown in which the bottom layer 16 is directly applied to the upstream side of the curtain as it leaves the hopper lip 36.
  • the bottom layer 16 is discharged from an additional slot 30.
  • This slot 30 is formed by inserting a sub-lip element 32 beneath the overhang 34 at the front of the hopper slide 28. In this case, the slot exit is positioned exactly at the hopper lip 36 as shown.
  • the slot 38 can be recessed to form a short slide 40 (of 1cm or less) on the underside of the hopper lip 36.
  • the hopper slide 28 is oriented conventionally in the coating direction as shown in Figure 4 so that the liquid leaving the slots 30, 38 becomes the bottom layer of the liquid material being coated.
  • the curtain forming hopper is usually oriented in the direction of web travel and the bottom layer is discharged from the bottom slot (i.e. the slot nearest the lip) . If this is used for a low viscosity bottom layer such as water, then the coatings are subject to longitudinal and transverse lines and streaks which are just as unacceptable as those seen in bead coating with the same arrangement.
  • the hopper slide is inclined at an angle of less than 30° to the horizontal, and the flow rate of the low viscosity liquid layer discharged from the top slot is restricted to not more than one third of the sum of the flow rates of that layer and the high viscosity layer immediately beneath it.
  • the slide surface 16 promotes levelling of any unevenness in the water layer, and the flow on the slide surface is sufficiently stable against waves and other manifestations of slide instability.
  • curtain processes according to the present invention it is possible, therefore, by using curtain processes according to the present invention, to provide uniform multilayer coatings at higher speeds than previously attainable.
  • curtain coating is employed, there is flexibility in the choice of flow rate and the viscosities for the layers forming the bulk of the coating.
  • the coating method according to the invention is both product tolerant and easy to engineer with minimum changes in current technology. Examples of coatings produced using a curtain coating process according to the present invention are now described in the following examples:-
  • the high viscosity layers comprised an aqueous solution of gelatin having a viscosity of 74mPas at 44°C.
  • the maximum coating speed of the gelatin layers alone was typically 324mmin at a
  • a low viscosity bottom layer 1.1mm in thickness, comprising water containing suitable surfactants, and having a surface tension of 21mNm and a viscosity of 0.61mPas at 4 °C
  • uniform coatings were achieved at speeds up to 596mmin ⁇ with gelatin layers having a combined thickness of 45mm.
  • the thickness of the gelatin layers could be substantially increased by coating at a forward application angle. For example, at an application angle of +20°, uniform coatings of gelatin layers having a combined thickness of 96m were made at speeds of up to 600mmin with a low viscosity bottom layer of 4.3mm.
  • uniform coatings were obtainable with low viscosity bottom layers having thicknesses in the range 1 to 8mm, although some successful coatings were made with bottom layers of only 0.5mm.
  • Example 2 The high viscosity layers comprised an aqueous solution of gelatin having a viscosity of 64mPas at 45°C. At a curtain height of 12.7cm and an application angle of +25°, the maximum coating speed of the gelatin layers alone was typically 376mmin at a total wet thickness of 44.3mm. Higher coating speeds produced severe air-entrainment.
  • the high viscosity layers comprised aqueous solutions of gelatin having viscosities of 67.1mPas and 63.2mPas at 42°C.
  • the maximum practical coating speed of the gelatin layers alone was typically 313mmin at a total wet thickness of 179mm. Higher coating speeds were prone to air-entrainment.
  • a low viscosity bottom layer comprising water containing suitable surfactants, and having a surface tension of 19.3mNm and a viscosity of 0.63mPas at 42°C
  • uniform coatings were achieved at speeds up to 738mmin with gelatin layers having a combined thickness of 76mm and a bottom layer thickness of 2.6mm.
  • Coating speeds of up to 600mm ⁇ n were achieved with a bottom layer thickness of 1.1mm and gelatin layers having a total thickness of 93mm.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)

Abstract

Dans le domaine du couchage par projection, on connaît l'utilisation d'une couche de fond ou d'accélération pour faciliter l'humectage d'un support en mouvement sur lequel on est en train de déposer un matériau liquide comprenant une ou plusieurs couches. Bien que l'on puisse atteindre des vitesses élevées de couchage, il est difficile de faire couler sur le glissoir incliné d'une trémie une couche de fond à faible viscosité et à débit relativement peu élevé sans provoquer la formation de vagues ou d'autres manifestations d'un écoulement instable. On a mis au point un procédé amélioré de couchage par projection selon lequel on utilise une couche de fond à faible viscosité permettant le dépôt simultané de liquides à viscosité élevée sur un support en mouvement en évitant les problèmes associés aux procédés connus de couchage par projection.
EP92901417A 1990-12-20 1991-12-16 Procedes de couchage Expired - Lifetime EP0563148B1 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
GB9027675 1990-12-20
GB909027675A GB9027675D0 (en) 1990-12-20 1990-12-20 Coating processes
PCT/EP1991/002416 WO1992011095A1 (fr) 1990-12-20 1991-12-16 Procedes de couchage

Publications (2)

Publication Number Publication Date
EP0563148A1 true EP0563148A1 (fr) 1993-10-06
EP0563148B1 EP0563148B1 (fr) 1994-10-26

Family

ID=10687354

Family Applications (1)

Application Number Title Priority Date Filing Date
EP92901417A Expired - Lifetime EP0563148B1 (fr) 1990-12-20 1991-12-16 Procedes de couchage

Country Status (5)

Country Link
EP (1) EP0563148B1 (fr)
JP (1) JPH06503753A (fr)
DE (1) DE69104850T2 (fr)
GB (1) GB9027675D0 (fr)
WO (1) WO1992011095A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6579569B2 (en) * 2001-02-28 2003-06-17 Eastman Kodak Company Slide bead coating with a low viscosity carrier layer

Families Citing this family (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA2209919A1 (fr) * 1995-02-02 1996-08-08 The Minnesota Mining & Manufacturing Company Procede et dispositif d'application de bandes minces de revetement liquide
FR2734178B1 (fr) * 1995-05-19 1997-06-20 Kodak Pathe Procede et appareil pour ameliorer l'uniformite d'un rideau liquide dans un systeme d'enduction au rideau
US6475572B2 (en) 2000-04-06 2002-11-05 3M Innovative Properties Company Electrostatically assisted coating method with focused web-borne charges
US6368675B1 (en) 2000-04-06 2002-04-09 3M Innovative Properties Company Electrostatically assisted coating method and apparatus with focused electrode field
US7473333B2 (en) 2002-04-12 2009-01-06 Dow Global Technologies Inc. Process for making coated paper or paperboard
US7364774B2 (en) * 2002-04-12 2008-04-29 Dow Global Technologies Inc. Method of producing a multilayer coated substrate having improved barrier properties
DE102008014863A1 (de) * 2008-03-18 2009-09-24 Polytype Converting S.A. Vorhangbeschichten mit Bend-Back-Reduzierung
JP5519629B2 (ja) * 2008-03-26 2014-06-11 スリーエム イノベイティブ プロパティズ カンパニー ２種以上の流体をスライド塗布する方法
US20110059249A1 (en) * 2008-03-26 2011-03-10 3M Innovative Properties Company Methods of slide coating two or more fluids

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4569893A (en) * 1983-08-29 1986-02-11 Canon Kabushiki Kaisha Amorphous matrix of silicon and germanium having controlled conductivity

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See references of WO9211095A1 *

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6579569B2 (en) * 2001-02-28 2003-06-17 Eastman Kodak Company Slide bead coating with a low viscosity carrier layer

Also Published As

Publication number Publication date
WO1992011095A1 (fr) 1992-07-09
GB9027675D0 (en) 1991-02-13
EP0563148B1 (fr) 1994-10-26
DE69104850D1 (de) 1994-12-01
DE69104850T2 (de) 1995-05-24
JPH06503753A (ja) 1994-04-28

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